Patents by Inventor Men G. Chu
Men G. Chu has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20160008881Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.Type: ApplicationFiled: September 21, 2015Publication date: January 14, 2016Inventors: Men G. Chu, Ho Yu, Alvaro Giron, Kenneth Joseph Kallaher, Jeffrey J. Shaw
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Publication number: 20150165518Abstract: Molten metal of a first composition is fed into a mold cavity, via a first control apparatus, wherein the control apparatus is open, wherein the feeding comprises flowing out of a first feed chamber. The first control apparatus is closed. A second control apparatus is opened. Molten metal of a second composition is fed into the mold cavity, via the second control apparatus, wherein at least a portion of the metal of the first composition in the mold cavity is sufficiently molten so that an initial feed of molten metal of the second composition mixes with the molten metal of the first composition in the mold cavity, wherein the feeding comprises flowing out of a second feed chamber, wherein the second composition is different from the first composition.Type: ApplicationFiled: March 2, 2015Publication date: June 18, 2015Inventors: Men G. Chu, Ralph R. Sawtell, Ronald E. Boylstein
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Patent number: 9038702Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.Type: GrantFiled: August 20, 2013Date of Patent: May 26, 2015Assignee: Alcoa Inc.Inventors: Men G. Chu, Jeffrey J. Shaw
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Patent number: 8997833Abstract: Molten metal of a first composition is fed into a mold cavity, via a first control apparatus, wherein the control apparatus is open, wherein the feeding includes at least flowing out of a first feed chamber. The first control apparatus is closed. A second control apparatus is opened. Molten metal of a second composition is fed into the mold cavity, via the second control apparatus, wherein at least a portion of the metal of the first composition in the mold cavity is sufficiently molten so that an initial feed of molten metal of the second composition mixes with the molten metal of the first composition in the mold cavity, wherein the feeding includes at least flowing out of a second feed chamber, wherein the second composition is different from the first composition.Type: GrantFiled: May 23, 2013Date of Patent: April 7, 2015Assignee: Aloca Inc.Inventors: Men G. Chu, Ralph R. Sawtell, Ronald E. Boylstein
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Publication number: 20140178590Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.Type: ApplicationFiled: February 27, 2014Publication date: June 26, 2014Applicant: Alcoa Inc.Inventors: Men G. Chu, Jeffrey J. Shaw
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Publication number: 20130337177Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.Type: ApplicationFiled: August 20, 2013Publication date: December 19, 2013Applicant: Alcoa Inc.Inventors: Men G. Chu, Jeffrey J. Shaw
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Publication number: 20130248133Abstract: Molten metal of a first composition is fed into a mold cavity, via a first control apparatus, wherein the control apparatus is open, wherein the feeding comprises flowing out of a first feed chamber. The first control apparatus is closed. A second control apparatus is opened. Molten metal of a second composition is fed into the mold cavity, via the second control apparatus, wherein at least a portion of the metal of the first composition in the mold cavity is sufficiently molten so that an initial feed of molten metal of the second composition mixes with the molten metal of the first composition in the mold cavity, wherein the feeding comprises flowing out of a second feed chamber, wherein the second composition is different from the first composition.Type: ApplicationFiled: May 23, 2013Publication date: September 26, 2013Applicant: ALCOA INC.Inventors: Men G. Chu, Ralph R. Sawtell, Ronald E. Boylstein
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Patent number: 8534344Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.Type: GrantFiled: March 31, 2009Date of Patent: September 17, 2013Assignee: Alcoa Inc.Inventors: Men G. Chu, Jeffrey J. Shaw
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Patent number: 7951468Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.Type: GrantFiled: March 31, 2008Date of Patent: May 31, 2011Assignee: Alcoa Inc.Inventors: Men G. Chu, Ho Yu, Alvaro Giron, Kenneth Joseph Kallaher, Jeffrey J. Shaw
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Publication number: 20110100579Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.Type: ApplicationFiled: December 31, 2010Publication date: May 5, 2011Inventors: Men G. Chu, Ho Yu, Alvaro Giron, Kenneth Joseph Kallaher, Jeffrey J. Shaw
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Publication number: 20100247954Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.Type: ApplicationFiled: March 31, 2009Publication date: September 30, 2010Inventors: Men G. Chu, Jeffrey J. Shaw
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Publication number: 20080182122Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.Type: ApplicationFiled: March 31, 2008Publication date: July 31, 2008Inventors: Men G. Chu, Ho Yu, Alvaro Giron, Kenneth Joseph Kallaher, Jeffrey J. Shaw
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Patent number: 7377304Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.Type: GrantFiled: July 11, 2006Date of Patent: May 27, 2008Assignee: Alcoa Inc.Inventors: Men G. Chu, Ho Yu, Alvaro Giron, Ken Kallaher, Jeffrey J. Shaw
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Patent number: 7264038Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.Type: GrantFiled: July 12, 2005Date of Patent: September 4, 2007Assignee: ALCOA Inc.Inventors: Men G Chu, Ho Yu, Alvaro Giron, Ken Kallaher
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Patent number: 7000676Abstract: A DC casting mold for casting molten metal alloy comprising a cooled tubular body that has a thermally insulated insert attached to its top surface. The thermally insulated insert has a bottom portion with a beveled sidewall, which forms an angle with the horizontal melt surface layer of the molten metal and creates an eddy. The eddy causes a substantial number of oxides that are formed during the casting process to remain in the bottom sidewall portion of the thermally insulated insert of the mold, thereby substantially reducing the number of ingot surface imperfections that promote ingot cracking. In addition, the eddy promotes break-up of the oxides into smaller pieces as the oxides flow toward the cooled inner walls of the cooled tubular body, thereby having limited surface area for growth of oxide folds. A method of casting molten metal alloys with improved surface quality is also disclosed.Type: GrantFiled: June 29, 2004Date of Patent: February 21, 2006Assignee: Alcoa Inc.Inventors: Men G. Chu, Alvaro Giron, William A. Casada, Ho Yu
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Patent number: 6386266Abstract: A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.Type: GrantFiled: July 7, 2000Date of Patent: May 14, 2002Assignee: Alcoa Inc.Inventors: Men G. Chu, William P. Chernicoff
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Patent number: 6250362Abstract: A method and apparatus is provided for producing a porous metal. The method broadly includes the steps of first, providing a molten metal and second, introducing a gas into said molten metal. The method then includes spray casting the molten metal containing the gas onto a surface thereby producing the porous metal. The method further provides for controlling the amount and size of the porosity contained within the porous metal by controlling the parameters at which the gas is introduced into the molten metal, as well as, controlling the parameters surrounding the spray casting of the molten metal. Additionally, the method also provides for producing a porous metal having either an isolated or interconnected pore structure. The present invention also provides for a porous metal product, as well as a porous aluminum alloy product, made by the described method. The apparatus includes a means for containing the molten metal wherein the containing means has a discharge end.Type: GrantFiled: March 2, 1998Date of Patent: June 26, 2001Assignee: Alcoa Inc.Inventors: Roberto J. Rioja, Men G. Chu, Gregory J. Hildeman, David D. Leon, Robert L. Kozarek
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Patent number: 6135198Abstract: A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.Type: GrantFiled: March 5, 1998Date of Patent: October 24, 2000Assignee: Aluminum Company of AmericaInventors: Men G. Chu, William P. Chernicoff
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Patent number: 5370171Abstract: The die casting machine includes a trough containing a supply of molten metal and a feed tube extending into the supply of molten metal in the trough. A flow of molten metal is maintained in the trough past the feed tube independent of the transfer of molten metal through the feed tube. The die casting machine further includes a filtering system.Type: GrantFiled: September 20, 1993Date of Patent: December 6, 1994Assignee: Aluminum Company of AmericaInventors: James R. Fields, Men G. Chu, Lawrence W. Cisko, C. Edward Eckert, Thomas R. Hornack, Marshall A. Klingensmith, Richard A. Manzini, M. K. Premkumar, Gerald D. Scott, Mohammad A. Zaidi
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Patent number: 5076344Abstract: This invention provides improved casting processes, equipment, and products. The invention is especially advantageous for die casting.Type: GrantFiled: March 7, 1989Date of Patent: December 31, 1991Assignee: Aluminum Company of AmericaInventors: James R. Fields, Men G. Chu, Lawrence W. Cisko, C. Edward Eckert, George C. Full, Thomas R. Hornack, Thomas J. Kasun, Jerri F. McMichael, Richard A. Manzini, Janel M. Miller, M. K. Premkumar, Thomas J. Rodjom, Gerald D. Scott, William G. Truckner, Robert C. Wallace, Mohammad A. Zaidi